Apparatus for cell construction



Nov. 26, 1963 J v CARLISLEETAL 3,111,771

APPARATUS .FOR CELL CONSTRUCTION 2 Sheets-Sheet 1 Filed Nov. 21, 1960 11v VENTORS JA MES u CARL/5L5 rusaoms u. ARA/0L0 Nov. 26, 1963 Filed NOV. 21, 1960 J. V. CARLISLE ETAL APPARATUS FOR CELL CONSTRUCTION 2 Sheets-Sheet 2 INVENTOR JAMES M. CARL/SL5 THEODORE M. ARNOLD ATTORNEY United States Patent 3,111,771 APPARATUS FOR CELL CONTRUCT1ON James V. Carlisle, Baton Rouge, La., and Theodore M.

Arnoid, Punta Gorda, Fia., assignors to Ethyl Qorporation, New York, N.Y., a corporation of Virginia Filed Nov. 21, 1960, Ser. No. 70,804 4 Claims. (Cl. 33-180) This invention relates to a new and novel method for the construction of electrolytic cells, and in particular it relates to apparatus used for the construction of these cells.

The manufacture of sodium and other alkali metals is carried out in an electrolytic cell basically similar to the Downs cell described in US. Patent 1,501,756. Briefly, the cell includes a housing containing one or more cylindrical anodes each of which is projected into openings contained within, or is in other words surrounded by a cylindrical cathode. In the annular space which is formed between an anode and the surrounding internal surface of the cathode is positioned a foraminous diaphragm supported from above by a collector. The collector, a unitary assembly, includes an outlet port for removal of the gaseous halogen, and also an annular inverted channel for mani'folding and for the removal of the alkali metal. This collector is supported by a frame which in turn is attached to and supported by the cell housing.

The concentricity and vertical disposition of the surfaces of the anodes with the surrounding diaphragm and surrounding cathode surfaces is an important attribute of a properly constructed cell. Attaining this objective has been a long standing problem in the industry. Inherent difliculties in the construction of these cells has been the lack of a suitable method for positioning the cathode with respect to the anode, and for positioning the diaphragm within the annular space between anode and cathode. Because the cathode and the diaphragm surround substantially the entire length of the anode, it is quite difficult to position the diaphragm concentrically between the cathode and anode within proper tolerances so as to provide a cell capable of the most efiicient operation. The difiiculty in maintaining concentricity between anode, cathode and diaphragm can be appreciated when it is noted that ordinarily the lateral distance between the anode and cathode is of the order of only 1 /2 inches as compared with the entire length of the anode, which is about 3 to 4 feet or more in length. In addition, for best operation the diaphragm must be inserted equidistant from the anode and cathode over the entire length of the anode. Prior methods employed for achieving this result have not been adequate. Generally speaking, the life period, that is the time period of operation before the cell need be broken down for rebuilding, has been erratic and necessitated completely dismantling the cell to replace the diaphragm. Such dismantling and reconstruction, in addition to being in herently expensive, also results in reducing production capacity of a plant. This arises from the fact a shop or plant has a certain number of stalls or locations for occupancy by as many cells; when a cell is being torn down and rebuilt, it is then not possible to merely insert a spare into that operating space.

Until the present invention, the techniques in cell building left much to be desired, as above explained. Consequently, it is an object of the present invention to provide apparatus for the rapid and accurate construction of an electrolytic cell. A further object of this invention is to provide apparatus to be employed in constructing an electrolytic cell which will provide a cell having a longer life, higher efiiciency, and increased produc- 3,111,771 Patented Nov. 26, 1963 "ice tivity. Another object of the present invention is to provide apparatus (for the accurate positioning and attach ment of an upper cell assembly with a lower cell as sembly. In particular, it is an object to provide a transport apparatus for transporting a collector-collector support frame-diaphragm sub-assembly and for the lowering and attachment of the said sub-assembly upon a complete base assembly to form a substantially complete cell. Other objects will be apparent from the discussion hereinafter.

The apparatus of the present invention is capable of assuming a variety of forms, and can be used in conjunction with other apparatus, as will be readily understood from the details given hereinafter and in the accompanying figures wherein,

FIGURE 1 shows in exploded fashion the major components of a cell, the sequence of assembly of the components into a completed cell, and the relation of the apparatus of the present invention to other apparatus and to the several major components or sub-assemblies of a cell, and

FIGURE 2 is an isometric view, partially sectioned, of a transport apparatus, hereinafter referred to as Jig F, for transporting and lowering the sub-assembly of the collector, collector support frame, and diaphragms to the complete base sub-assembly.

The apparatus, Jig F, of the present invention comprises a hollow shell member or jig body, the diameter or plan or" which corresponds generally with the shell plan of a complete base assembly. Within the internal opening of the jig body is located a vertically adjustable slide carriage for the engagement with and transport of a collector-collector support frame-diaphragm sub-assembly. By lowering and engaging the slide carriage of the jig body with a collector-collector frame-diaphragm sub-assembly, the said assembly can be raised or hoisted within the jig body and held in such position while the entire apparatus is transported to and placed upon a cell base assembly. The jig body is then aligned upon the cell base with reference to certain indicia marks, then leveled. The collector-collector frame-diaphragm can then be lowered upon the cell base assembly and aifixed thereto to form a substantially complete cell.

It has been found that the apparatus of this invention, particularly in combination with other apparatus, provides an efiicient means for the construction of an electrolytic cell whereby the criticality of the positioning of the cathode with respect to the anodes, and the diaphra-gms with respect to the cathode and anodes, is achieved. The apparatus eliminates incorrect alignment of these integral parts which results, for example, in burning of the diaphragms and thus causing loss of production and unnecessary dismantling of the cell, which must be reconstructed. By the use of the apparatus of this invention, the efiiciency of the cell is considerably increased as evidenced by the fact that production is increased for a given current input. In addition, the average life of the diaphragm is appreciably increased, thereby reducing loss in production time.

The construction of a completed cell includes two major assembly sequences, the assemblies so-made being combined into a completed cell. One sequence of assembly operations permits format-ion of the lower portion of a cell. This sequence of operations thus provides for the formation of a complete base assembly by the addition of anodes to a cell base, then for the addition of a lower cell shell portion, then for the addition of a cathode, and then for the addition thereto of an upper or 'final cell shell portion, thus completing this major assembly.

Another sequence of assembly operations includes assembly of a collector and collector support frame to form a sub-assembly, and then the addition of diaphragm screens to that sub-assembly to form the upper portion of a cell, the second of the two major assemblies. These two assemblies are then combined to form a completed cell.

This entire sequence of assembly operation is schematically illustrated by reference to FIGURE 1 which shows the flow of separate cell components into subassemblies and the relationship of these components and sub-assemblies to the figures of the present invention. Referring to FIGURE 1, a set of anodes and a cell base are combined, using Jig C. The base assembly thus formed is then combined with a cell shell portion. A part of the cell lining is then added, and a cathode is then fitted to this base sub-assembly using a Jig D to provide proper spatial relations. To this assembly is then added an upper cell shell using Jig E to provide means for correct alignment. This sequence of operations completes the formation of one of the two major assemblies, viz., the formation of a complete base assembly, or the lower portion of a cell.

The other major sequence of assembly operations involves firstly the combination of a collector and collector support frame into a sub-assembly, using Jig A. This sub-assembly, and a set of diaphragms are then combined by the use of another apparatus, Jig B. This completes the second major sequence of operations and provides for the formation of a collector-collector framediaphragm assembly, the upper portion of a cell. This assembly is then transported in a transport Jig F and is combined with the base assembly to form a completed cell.

The apparatus of Jig F, schematically represented in FIGURE 1, is shown in FIGURE 2. Jig F includes a generally cylindrical body 181 having a diameter approaching or equivalent to a diagonal dimension of a cell. The internal diameter of the jig body 181 extends outside the straight side portion of the plan of a cell shell, which are generally built on a plan corresponding to a square with rounded corners. A portion of the upper cell shell 175 is shown in FIGURE 2. The jig body 181 is terminated by two reinforced flange members 182 182 and also is perforated by a plurality of sight and operating holes 183. These openings are appreciable in size permitting adjustment and operation within the jig body 131 as hereafter described.

Projecting inwardly from the flange members 182 182 are a plurality of lugs 184 184 184 184 usually eight in number, uniformly circumferentially placed about the inner margin of the flange members M2 152 Attached rigidly to these lugs are vertical slide bars 1%,, 186 186 186 A carriage frame 18% is provided within the jig body 131. The carriage is rigidly attached to a slide ring 137, which is provided with slide bearigns 18%, 188 equal in number to and slidable in the slide bars 186. The carriage frame 181) is also provided with a lift bolt 189 to which can be attached a crane hook for raising or lowering the carriage frame 186. The frame is also provided with four dogs or pivotally attached clamps 191 191 adapted to swing under the channel members 52 52 of a collector support frame 51. Clamp bolts 192 192 in the clamps 191 provide for rigidly attaching a collector support frame 51 to the under side of the carriage frame 180. It is seen that the lateral disposition and vertical alignment of a sub-assembly of a collector 41, a collector support frame 51, and diaphragms 99 can be maintained at any elevation with respect to the jig body 181.

Attached to the bottom of the jig frame 181 are four jack screws 193 193 projecting downwardly and providing a support for the jig. Mounted on the bottom flange 182 are several leveling glasses 194 194 so that 41 the jig body 181 can be adjusted vertically by adjustment of the jack screws 193 193 The plan or horizontal disposition of the jack screws 1% 193 is such that they correspond to the extensions 174 174 or projections inwardly from the upper portion of the cell shell 175.

In employing the Jig F in the construction of a cell, the "g is lowered to rest upon the Jig B (FIGURE 1), said jig having a completed collector-collector frame-diaphragm assembly therein. The Jig F is generally leveled by adjustment of the jack screws 193 1% and the lateral disposition of the jig is roughly adjusted. The slide carriage 131) is then lowered to contact the aforementioned assembly, and fastened securely thereto by the clamps 1511 191 and clamp bolts 192 B2 The slide carriage 189, with the attached assembly, is then raised within the Jig F and locked in place by locking means not shown.

The jig and enclosed assembly are then transported bodily to a complete base assembly, established as described with reference to FIGURE 1.. The jig is lowered onto the upper cell shell, the jack screws 193 19%;; engaging the extension plates 174 174 174.; projecting inwardly from the cell shell rim 176. After lowering the collector-collector support frame-diaphragm assembly to the cell, the slide carriage 139 is disconnected therefrom and the transfer Jig F is removed. The plan disposition of the assembly, with respect to the bottom assembly of a cell is then provided by indexing or aligning registration marks on the collector support frame and channels on the vertical planes established respectively by the notches 178 173 in the cell Z-bars and the marl: or slot 17%, in the cell shell rim. The Z-bars 177 177 having been previously adjusted for elevation, define a horizontal plane for support of the collector support frame 51. In practice, uniform thickness insulating blocks are inserted between the Z-bars and the ends of the collector frame channels 52, to electrically insulate the collector frame from the cell shell.

From the foregoing, is is seen that the use of various apparatus provides for the construction of a cell having a continuous explicit relationship between the collector frame, collector, diaphragms, anodes, and other portions of a cell. These relationships are established and preserved from the beginning of construction through to the final assembly step. Further steps to render a cell operable after assembly of a complete base assembly with a collector-collector frame-diaphragm assembly would include the connection of an appropriate chlorine line to the collector opening, and the attachment of the necessary electrical connections, etc.

In careful comparison of the performance of a group of cells constructed with the apparatus of our invention with performance of a group constructed according to previous methods it was found that the former group provided an increase of approximately 1.5 percent in currency efficiency. In addition, it was found that the average elfective life of the former group of cells was a significant improvement over the preceding practice, particularly with respect to the diaphragm life. Since the cost of construction of cells with the present apparatus is substantially the same as by the former practices, it is apparent that our apparatus is highly beneficial and economical.

Having described the apparatus of our invention in some detail and the manner of its use, what we claim is:

1. Apparatus for the transport, alignment and assembly of a collector-collector support frame-diaphragm subassembly with a cell base sub-assembly to form a substantially complete cell comprising a generally cylindrical body within which a slide carriage is flexibly mounted, said cylindrical body being of a diameter equivalent to a diagonal dimension of a cell, the cylindrical body being flanged at both ends and being perforated by a plurality of sight and operating holes, and having projecting inwardly from the flange members a plurality of lugs uniformly circumferentially spaced within the cylindrical body each supporting vertical slide bars upon which the slide carriage is flexibly mounted, said slide carriage being rigidly attached to a slide ring which is provided with slide bearings equal in number to the number of slide bars, said slide carriage thus being movable along the cylindrical body for transport and lateral and vertical alignment of a collector-collector support -frame-diaphragm subassembly with a cell base sub-assembly.

2.. Apparatus for the orientation and attachment of a collector-collector support frame-diaphragm assembly upon a complete cell base assembly comprising a cylindrical shell body having an internal diameter within which is mounted a vertical movable slide carriage, said slide carriage including a carriage frame rigidly attached to a slide ring which is concentric with the internal opening of the shell body and provided with slide bearings slidable upon and equal in number to a plurality of vertically mounted slide bars which are uniformly, vertically and eircumferentially spaced around the inside diameter of the cylindrical shell body so that the slide carriage is free to move vertically within the cylindrical shell body whereby the slide carriage can be lowered into engagement with and attached to a collector-collector support framediaphragm assembly, the said assembly elevated into the cylindrical body and the entire body and assembly transported to and oriented with a cell base assembly and the collector-collector support frame-diaphragm assembly attached therewith.

3. Apparatus for the transport, alignment and assembly of a collector-collector support frame-diaphragm subassembly with a cell base sub-assembly to form a substantially complete cell comprising a generally cylindrical body within which a slide carriage is flexibly mounted, said cylindrical body being of a diameter equivalent to a diagonal dimension of a cell, the cylindrical body being flanged at both ends and being perforated by a plurality of sight and operating holes, and having projecting inwardly from the flange members several lugs uniformly circumferentially spaced within the cylindrical body each supporting vertical slide bars to which is slidably attached a slide ring, which slide ring is provided with rigidly attached slide bearings equal in number to and slidable on the slide bars, the slide carriage being a generally rectangular frame member rigidly attached to the slide ring so that the carriage is axially movable within the cylindrical body, the underside of said carriage being provided with a plurality of clamps and clamp bolts which permit the securement of a collector-collector support frame diaphragm sub-assembly upon the lower side thereof whereupon the said sub-assembly can be raised to any elevation within the cylindrical body and the entire unit transported for lateral and vertical alignment of the collector-collector support frame-diaphragm sub-assembly with a cell base sub-assembly.

4. The apparatus of claim 3 wherein there is included upon the lower flange of the cylindrical body a plurality of jack screws and several leveling glasses for leveling and adjusting the complete assembly upon a cell base subassembly.

References Cited in the file of this patent UNITED STATES PATENTS 2,710,696 Fontaine et a1 Jan. 14, 1955 

1. APPARATUS FOR THE TRANSPORT, ALIGNMENT AND ASSEMBLY OF A COLLECTOR-COLLECTOR SUPPORT FRAME-DIAPHRAGM SUBASSEMBLY WITH A CELL BASE SUB-ASSEMBLY TO FORM A SUBSTANTIALLY COMPLETE CELL COMPRISING A GENERALLY CYLINDRICAL BODY WITHIN WHICH A SLIDE CARRIAGE IS FLEXIBLY MOUNTED, SAID CYLINDRICAL BODY BEING OF A DIAMETER EQUIVALENT TO A DIAGONAL DIMENSION OF A CELL, THE CYLINDRICAL BODY BEING FLANGED AT BOTH ENDS AND BEING PERFORATED BY A PLURALITY OF SIGHT AND OPERATING HOLES, AND HAVING PROJECTING INWARDLY FROM THE FLANGE MEMBERS A PLURALITY OF LUGS UNIFORMLY CIRCUMFERENTIALLY SPACED WITHIN THE CYLINDRICAL BODY EACH SUPPORTING VERTICAL SLIDE BARS UPON WHICH THE SLIDE CARRIAGE IS FLEXIBLY MOUNTED, SAID SLIDE CARRIAGE BEING RIGIDLY ATTACHED TO A SLIDE RING WHICH IS PROVIDED WITH SLIDE BEARINGS EQUAL IN NUMBER TO THE NUMBER OF SLIDE BARS, SAID SLIDE CARRIAGE THUS BEING MOVABLE ALONG THE CYLINDRICAL BODY FOR TRANSPORT AND LATERAL AND VERTICAL ALIGNMENT OF A COLLECTOR-COLLECTOR SUPPORT FRAME-DIAPHRAGM SUB-ASSEMBLY WITH A CELL BASE SUB-ASSEMBLY. 